Wall system

ABSTRACT

A wall system includes a first wall section a structural portion, such as concrete block construction. A second wall section mounts to the first wall section and includes insulating panels connected in an edge to edge relationship to form a continuous insulating layer. A third wall section of conventional finishing materials such as sheetrock or paneling mounts over the second wall section. Each of the insulating panels includes mounting elements embedded therein that provide for mounting the panels to the first layer and for mounting the third wall section to the second wall section. Each of the panels is lightweight and may be water impervious. The panels have ridges formed therein that define channels for routing wiring and other components. The panels also include complementary edges and complementary alignment features.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a wall system and in particular to a wall finishing system providing combined insulation and mounting onto a masonry wall.

2. Description of the Prior Art

Conventional wall systems for basements and other applications wherein a masonry wall is used have traditional wood frame construction with wood studs and fiberglass insulation placed against the concrete block or other masonry between the studs. Such construction systems are well known and utilized widely.

Although such systems are proven to be suitable and often provide satisfactory finishing, such systems have several drawbacks. Installation may be difficult with wood studs mounting to a masonry wall. The studs may warp or twist and may cause the nails to protrude back through sheetrock. The wood studs are prone to mold, moisture damage and rot and require an additional vapor barrier. Although insulation may be placed between the studs, the studs themselves are still a thermal conductor. Steel studs are an alternative, but generally prove difficult for the average homeowner to install and require special mounting.

Fiberglass insulation is also susceptible to water damage and mold if moisture is present. The thickness required for adequate insulation may decrease the overall size of the room due to the added depth of the wall. Fiberglass insulation is difficult to handle and requires special gloves and a respirator. Foam types of insulation are often open cell material that allows moisture to pass through.

Common stud and rolled insulation systems also suffer from difficult installation for wiring, switches, tubing and other components. Conventional construction requires drilling through the studs for routing wiring and/or tubing along the wall.

To overcome the problems associated with common wood stud construction, systems have been developed to provide an insulation layer. Such systems typically use panels that may attach to one another. Some panels may include metal studs formed therein to allow for mounting. Although such systems do provide advantages in many applications over traditional construction, these systems suffer from their own disadvantages. Such systems require unwieldy, large panels and do not provide alignment along all edges. In addition, such systems do not provide for quick and simple mounting using traditional techniques such as screws or glue strips. Moreover, such systems do not provide for drains or channels to allow water to easily drain without passing through to the inner side of the panels. Such systems also do not provide for easily routing wiring, tubing and other elements that are installed.

It can be seen then that a new and improved wall finishing system is needed. Such a wall finishing system should provide simple, inexpensive and easy to install construction. In addition, such a system should provide for easily routing tubing, wiring and other components into the wall. Such a system should provide for improved insulation and mounting of sheetrock, paneling or other innermost layers. The present invention addresses these, as well as others associated with wall systems.

SUMMARY OF THE INVENTION

The present invention is directed to a wall system and in particular to a wall finishing system suitable for masonry and other similar wall construction. The present invention utilizes foam insulating panels that are connected to form an intermediate wall layer. The panels include mounting stud type elements molded into the panels to reduce cost and to eliminate problems associated with traditional wood frame construction with rolled fiberglass insulation.

According to the present invention, a load bearing or structural wall portion such as concrete blocks or other masonry as is often found in basements of many homes is covered by an insulating layer and then an inner finishing layer that may be painted, wallpapered, paneled or finished in other well known techniques. The panels have molded in mounting elements that are spaced apart the same distance as standard wood studs and allow for fastening with glue and conventional hardware to the structural wall. The mounting elements also provide for attachment of sheetrock, wood paneling and other inner finishing type layers to the insulating panel layer.

The panels are generally made of water impervious foam material so that the panels are lightweight and easily transported. In typical embodiments, the panels are 2 feet×4 feet or 16 inches by 4 feet, allowing for easily carrying the panels down stairways. The panels have a tongue and groove configuration along the edges for connecting to adjacent panels both vertically and horizontally to create a continuous insulating layer for an entire wall. The panels include alignment tabs and complementary notches along the top and bottom edges to ensure a proper engagement and placement.

The panels also have ridges formed on at least one face that define channels or chases for routing wiring, tubing or other elements. The parallel ridges extend vertically substantially across the height of the panels leaving only a small strip along the edges so that when panels are connected in an edge to edge relationship, a channel or chase is formed horizontally along adjacent panels between the ends of the ridges of adjacent panels. With this configuration, wiring and other elements may be routed both horizontally and vertically along the width and height of a wall without having to modify the panels. The panels also include cutting channels so that clean, straight cuts may be simply and quickly made so that the panels have clean straight edges.

The mounting elements are molded into the panels in an embedded configuration in one embodiment. In one embodiment, the mounting elements are generally elongate members with a somewhat “H” shaped cross-sectional profile. The first portion extends perpendicularly outward both its center, which abuts a series of center connecting ribs. The second portion extends from an opposite end of the connecting ribs in a substantially perpendicular configuration with a very slight obtuse “V” shaped profile. The first portion extends to a first face of the panel and includes a glue channel for receiving a bead of glue to mount the panel to an adjacent wall layer. The second portion also extends to a second face of the panel and includes glue channels on each outward extending leg and a center channel and also provides for receiving adhesive type materials. The mounting elements are preferably molded of plastic material that is impervious to rusting and other deterioration and that can provide a foundation for attaching mounting hardware and also provide support for the panel.

The wall system is easily installed. Preparations may require upgrading the floor to ensure that there is adequate drainage. The panels are then installed by gluing to the load bearing masonry wall. Panels are placed starting in one corner and working horizontally across the width of a wall. The tongues and grooves form connections between adjacent panels so that a continuous nearly water impervious layer is achieved. The panels are typically offset relative to adjacent panels above and below, but are correctly positioned and spaced with the alignment tabs and notches. Construction of the insulating layer continues in a row by row configuration until reaching the top of the wall. The panels are trimmed to remove the tongue and grooves from the edges abutting the floor, ceiling and corners for continuous total coverage of the masonry wall. After the glue dries, further hardware may be used for mounting to the load bearing wall. Sheetrock or other layers may then be connected using conventional hardware to the mounting elements. It can be appreciated that no special skills or special tools are needed for installation. Electrical boxes and other devices may be installed by simply cutting out the portions of a panel and connecting to the wiring or other elements extending through the channels formed by the panels.

The present invention is lightweight, durable, easy to install, long lasting, has improved insulation attributes, is inexpensive, can be retrofit and minimizes common drawbacks of traditional construction such as mold, water damage and other problems associated with the prior art.

These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views:

FIG. 1 is a perspective view of a wall system with portions removed for clarity according to the principles of the present invention;

FIG. 2 is a perspective view of a panel for the wall system shown in FIG. 1;

FIG. 3 is a front elevational view of the panel shown in FIG. 2;

FIG. 4 is an end view of the panel shown in FIG. 2;

FIG. 5 is a rear elevational view of the panel shown in FIG. 2;

FIG. 6 is a perspective view of a mounting element that is embedded in the panel shown in FIG. 2;

FIG. 7 is an opposite perspective view of the mounting element shown in FIG. 6;

FIG. 8 is a side elevational view of the mounting element shown in FIG. 6; and

FIG. 9 is an end view of the mounting element shown in FIG. 6.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings and in particular to FIG. 1, there is shown a wall system, generally designated 100. The wall system 100 is especially suited for masonry type walls, commonly found in basements and other areas where concrete block or similar construction is utilized. It can be appreciated however that the system 100 of the present invention may be adapted to many other types of applications.

The wall system 100 generally includes a first layer or section, often a load bearing or structural masonry wall 102 formed of concrete block or other similar building materials. An insulation layer 104 formed of interconnected panels, described hereinafter, mounts to the masonry wall layer 102 with glue or fasteners 112. A finishing inner layer, such as paneling, sheetrock or other finishing type material 106 mounts with fasteners 112, glue or other conventional mounting techniques to the insulating layer 104. A coating 108 such as paint, wallpaper or other final, exposed material that is visible covers the inner layer 106. The technique of the present invention provides for elimination of the conventional stud framing and roll-type insulation and provides improved R-value in a thinner layer, adding floor space and volume to the finished room. In addition, the present invention is less expensive and easier to install than prior conventional building systems and techniques.

The insulating layer 104 is formed from a number of rectangular insulating panels 120 mounted in an edge-to-edge relationship. The panels are generally rectangular and include tongues 130 and complementary grooves 132, such as shown most clearly in FIGS. 2 and 4, along the edges of the panel 120. The tongues and grooves 130 and 132 provide for alignment and connection along both the horizontal and vertical edges so that the panels 120 may be connected to extend horizontally and vertically in a continuous insulating layer. The panels 120 also include alignment tabs 134 and complementary notches 136 along the top and bottom edges that aid in aligning the panels for final orientation. In one embodiment, the panels 120 are made of a closed cell expanded polystyrene material. Such a material is lightweight, provides excellent insulation performance and is impervious to water. Moreover, such material may include a fire retarder. Although a vapor barrier may also be added to the system, it can be appreciated that with the insulating layer 104 made of a water impervious material and with interlocking edges, the need for a separate vapor barrier used in many applications may be eliminated.

Referring again to FIGS. 4-5, the panels 120 include a series of parallel ridges 122 formed on one face of the panel. The ridges 122 extend vertically when the panels 120 are mounted and provide first channels 124 that may serve as a wiring chase or for running tubing, fiber optics or other elements through the insulating layer without requiring cutting into the panels 120. The channels 124 also allow for water to drain. In addition, some of the channels are deeper, forming wiring chases 128. The ridges 122 extend substantially along a large part of the height of the panel 120, but stop short of one edge so that when the panels 120 are attached, horizontally extending channels 126 are formed. The horizontal channels 126 intersect with the vertical channels 124 providing for easy insertion and routing of wiring, tubing and other elements that are typically placed inside a wall. A cutting guide 138 also provides for trimming the panels 120 to a common size and provides a guide for forming a straight edge. It can be appreciated that in one embodiment, the panels are approximately 48 inches wide and 24 inches high (122×61 cm). A typical depth for a panel 120 is two inches (5 cm). Such a size provides for standard alignment and easily transporting the panels 120 down narrow staircases such as often lead to a basement.

The panels 120 also include mounting elements 150 that serve as studs embedded into the panels. In one embodiment, each panel 120 includes three embedded mounting elements 150. The mounting elements 150 extend vertically when the panels 120 are installed. The mounting elements 150 are placed at 16 inch (41 cm) centers as is typical with wood stud construction. The mounting elements 150 extend to a first face of the panels 120 and provide a surface for gluing as well as receiving conventional fasteners such as bolts, screws and/or nails. The mounting elements 150 are lightweight, but provide rigidity and strength to the panels 120.

As shown in FIGS. 6-9, each mounting element 150 is a substantially elongate, molded plastic element with a generally “H” shaped cross-sectional profile. The mounting element 150 includes a first mounting portion 152, a second opposed mounting portion 160, and a series of central ribs 154 connecting the first portion 152 and the second portion 160. The first portion 152 extends laterally outward from the ribs 154 at a generally right angle. A first face of the first portion 152 includes a glue channel 153 or glue channels transverse to the longitudinal direction. The ribs 154 include a first ridge portion 156 connecting to the first portion 152 and a second ridge portion 158 connecting to the second portion 160. The second mounting portion 160 includes leg sections 162 extending from either side of the center ribs 154 and extending slightly outward along the direction of the ribs. The leg sections 162 each include an outer channel 166. The second portion also includes a center channel 164 substantially aligned with the ribs 154. The channels 164 and 166 aid in anchoring the mounting element 150 into the panel 120. The outer channels 166 also serve as glue channels for mounting.

The mounting elements 150 are spaced apart generally in the same spacing as wood studs or other common spacing such as 8 inch or 12 inch intervals and provide a lightweight yet durable surface for receiving mounting hardware, as discussed above. The mounting elements 150 are also lightweight and molded and impervious to water for durable and inexpensive construction. It can be appreciated that the system of the present invention reduces the likelihood for water damage, mold and other problems that conventional building techniques are prone to, especially when set in a damp environment, such as a basement. It can further be appreciated that the present invention provides for easy trimming and cutting with a hand saw or simple knife. The materials used are not irritating to skin or eyes and do not require special gloves for handling as is needed for fiberglass systems. The materials are lightweight and of a size that is easier to handle than typical long wood studs and 4 feet by 8 feet sheets of sheetrock. Drywall does not need to be aligned with studs as in a convention techniques. Installation is much quicker and does not require special skills or tools. Moreover, the present invention can be retrofit to existing wall systems and provide improved insulating characteristics.

The wall system 100 of the present invention is also easy to install. Little preparation is needed but drain tile, if necessary, is installed before the system is in place. A bead of construction adhesive is placed in the gluing channel 160 on all three of the studs 150 on each panel 120. Installation generally starts in a lower corner of the wall with the panel 120 simply pressed onto the inner masonry wall 102. The panel 120 is then secured with a power fastening device or other conventional mounting hardware. Installation continues with the panels 120 being aligned and vertically extending tongues 130 inserting into corresponding grooves 132 until a bottom row of panels 120 extends across the wall. The panels 120 of the next row are generally offset from the previous row and placed starting along one edge and working along the row in a similar manner. The mounting elements 150 are aligned by the alignment tabs 134 inserting into the corresponding notches 136. Construction continues along horizontal rows until the entire wall is covered. The corners are accommodated by cutting off the tongues and/or grooves and butting the panels 120 together.

Spaces for receiving electrical boxes can be cut into the panels 120 using a standard drywall keyhole saw. Wiring and other elements can be run through the wall 100 by leading the wiring through the channels 124 and 126. When the panels 120 have been installed, the glue is generally allowed to dry for a period of time such as 24 hours. Once the glue sets, the sheetrock can be applied by using standard drywall screws attaching to the mounting elements 150. The wall 100 is finished in the same manner as conventional walls with mud and tape used with the drywall and an inner layer such as paint or wallpaper applied over the sheetrock. In some applications, paneling or other materials may be used rather than sheetrock. The method is typically faster and easier with less skill and fewer tools required than conventional construction techniques.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. A wall construction system, comprising: a plurality of molded insulating panels; a mounting element embedded in each of the insulating panels, wherein the mounting element comprises a first elongate portion, a second elongate portion, and a plurality of spaced apart connecting sections extending from the first portion to the second portion.
 2. A wall construction system according to claim 1, wherein the mounting element comprises a glue channel on an outer surface of the first elongate portion.
 3. A wall construction system according to claim 1, wherein second elongate portion of the mounting element comprises a first section extending substantially transverse to the connecting sections in a first direction and a second section extending substantially transverse to the ribs in a second direction away from the first direction.
 4. A wall construction system according to claim 1, wherein the first and second sections extend slightly away from the first elongate portion.
 5. A wall construction system according to claim 1, wherein the first and second sections define a plurality of longitudinally extending channels.
 6. A wall construction system according to claim 1, wherein the panel includes a plurality of mounting elements embedded in the panel.
 7. A wall construction system according to claim 6, wherein the plurality of mounting elements are aligned in a spaced apart parallel configuration.
 8. A wall construction system according to claim 1, wherein a first face of the panels includes a plurality of parallel ridges defining a plurality of channels there between.
 9. A wall construction system according to claim 1, wherein the panels comprise closed cell expanded polystyrene material.
 10. A wall construction system according to claim 1, further comprising alignment portions along at least two edges of each panel.
 11. A wall construction system according to claim 1, further comprising alignment portions along four edges of each panel.
 12. A wall construction system according to claim 1, wherein two edges of the panel comprise tongues and two edges of the panel comprise grooves.
 13. A wall construction system according to claim 1, wherein a portion of the mounting element is exposed through one surface of the panel.
 14. A wall construction system according to claim 1, further comprising alignment tabs along two first edges of each panel and complementary alignment notches along two second edges of each panel.
 15. A wall construction system according to claim 8, wherein the first face defines a second channel at the ends of the ridges when connected to another panel, wherein the second channel extends transverse to the first channels.
 16. A wall construction system according to claim 15, wherein the first channels intersect the second channel.
 17. A wall comprising: a first wall section comprising a structural portion; a second wall section mounting to the first wall section and comprising a plurality of insulating panels, wherein each of the insulating panels comprises a mounting element embedded therein; a third wall section proximate the second wall section; wherein the wall sections mount with attachment devices to the mounting elements.
 18. A wall according to claim 17, wherein the mounting element comprises a first elongate portion, a second elongate portion, and a plurality of spaced apart connecting sections extending from the first portion to the second portion.
 19. A wall construction system according to claim 17, wherein the panel includes a plurality of mounting elements embedded in the panel.
 20. A wall construction system according to claim 19, wherein the plurality of mounting elements are aligned in a spaced apart parallel configuration.
 21. A wall construction system according to claim 17, wherein a first face of the panels includes a plurality of parallel ridges defining a plurality of channels there between.
 22. A wall construction system according to claim 17, further comprising alignment portions along four edges of each panel.
 23. A method of making a wall, comprising: forming a first wall section, wherein the first wall section is a structural; mounting a second wall section over the first wall section, wherein the second wall section comprises a plurality of rectangular insulating panels interconnected in a continuous manner, and wherein each of the panels includes at least one mounting element embedded therein; mounting a third wall section over the second wall section; wherein the second wall section attaches to the first wall section at the mounting element and wherein the third wall section attaches to the second wall section at the mounting element.
 24. A method according to claims 23, wherein each of the mounting elements comprises a first elongate portion, a second elongate portion, and a plurality of spaced apart connecting sections extending from the first portion to the second portion.
 25. A method according to claim 23, wherein each of the panels comprises complementary connectors along the edges of the panels, and wherein the panels are connected to one another in an edge to edge configuration.
 26. A method according to claim 23, wherein a first face of the panels includes a plurality of parallel ridges defining a plurality of channels there between and wherein elements are routed in the channels prior to mounting the third wall section. 